“Road Vehicles — Endurance Braking Systems of Motor Vehicles and Towed Vehicles

Presentation to GRRF, 55th Session, Geneva Febr. 3rd, 2004

ISO CD 12161 Doc TC22/SC2 N 597 “Road vehicles — Endurance braking systems of motor vehicles and towed vehicles — Test procedures”

by ISO TC22/SC2/WG6 SWG 6 „Endurance braking systems“

Dr. Reinhold Pittius (VOITH TURBO)

Pittius 2004-02-03 page 1

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 1. Structure of ISO Working Group

Subworking group SWG 6 „Endurance braking systems“ Chairman Dr. Reinhold Pittius

• reporting to ISO 22/2/WG6 „Braking Systems“ Chairman Prof. v. Glasner

• Active members of SWG 6: DaimlerChrysler TELMA IVECO VOITH TURBO MAN ZF

• Status - Working Draft agreed by TC22 Æ Committee Draft (CD) - Distribution as ISO DIS in Dec. 2003 - Balloting until May 2004 Pittius 2004-02-03 page 2

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 Contents

1. Structure of ISO Working Group 2. The Target 3. Basic legal requirements 4. Basic understanding of equivalent energy 5. Specific properties of different types of retarders 6. Test methods 7. Conclusion

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 2. The Target

Standardization

• of testing procedures • of vehicles - equipped with endurance braking systems - to be type approved • according to existing legal requirements

¾ Detailed description of ¾ different test methods such that ¾ results are • objectiv, • realistic and • compatible

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (1)

ECE-R 13, Annexe 4

6 km para. 1.6 Type II

30 km/h 6 %

para 1.8 Type IIA service brakes 6 km must not be used !

30 km/h 7 %

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (2)

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (3)

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 3. Basic legal requirements (4)

= Equivalent same in the energy ! average same time power !

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 4. Basic understanding (1)

Key philosophy of ISO CD 12161 with regard to the standardization of performance tests of endurance braking systems

= Equivalent same in the energy ! average same time power ! W = m*g*∆H 1) P = W / t t = L / v = m*g*L*tan α 1) rolling resistance to be considered! Pittius 2004-02-03 page 9

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 4. Basic understanding (2)

- Downhill test (preference IVECO)

Eq uival ent Y E - Towing test es ner Æ gy (preference MAN) A in ppr t ov im a e ? l ! - Test bench (preference DC)

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 5 Specific properties of different types of retarders (1)

Engine brake vs secondary (hydrodynamic) retarder

-1 Getriebe: ZF S6-90 nMot-min/max 1200 / 2000 min Rdyn 0,502 m Masse 18000 kg iHa 3,33 fr 1,0 %

Bremsmoment [Nm] Verzögerung [%] 5.000 100 kW 200 kW 300 kW 400 kW 500 kW 600 kW 19,0

4.500 Comparison Exhaust Brake vs Secundary Retarder 17,0 • Torque vs speed 1. Gang 4.000 15,0 3.500 Average (engine = 1600 min-1) • Power vs speed Voith Retarder 133-2 (3750Nm) 13,0 3.000

• controllability 2. Gang 11,0 2.500

9,0 2.000

Type IIa 7,0 1.500 3. Gang●

1.000 4. Gang 5,0

5. Gang 500 3,0 6.Gang

Source: Voith Analysis 0 1,0 0 102030405060708090100v [km/h] Pittius 2004-02-03 page 11

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 5 Specific properties of different types of retarders (2)

Electromagnetic vs hydrodynamic retarder

oil

Thermal performance

stator rotor

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 5 Specific properties of different types of retarders (3)

Service Brake Electromagnetic Retarder Hydrodynamic Retarder

elimination elimination continus braking capability continus braking capability through through cooling cooling time limited time limited time limited system system

capacitive radiation capacitive radiation capacitive radiation absorption via absorption via absorption via surface surface surface

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.1 Test methods – Downhill test (1)

Specific criterias:

There is no real downhill track having exactly 7% and 6km length Perhaps the height difference is available, but not Only small tolerances on exactly the length (resp. CD 12161 equivalant energy and time ! the slope) • tolerances on slope variation Even if the height and the but lenght are correct, the • compensation on average slope slope may vary along the track. • compensation on height difference

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.1 Test methods – Downhill test (2)

Height profile of a realistic test track

850 810 m über NN) Parkplatz Torfhaus bei km 11,3 ( . . . . . 800 . . Height [m] . . . . 750 . Height Profile of . . . Road B4 near . 700 . Fgeedmessen . . . Torfhaus . . . . 650 Akima-Fkt...... 600 . . . LZA bei km 8,0 (620 m über NN) ...... 550 ...... 500 ...... 450 ...... 400 . . . bei km 4,0 (370 m über NN) . . . Parkplatz Steinbruch 350 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 Pittius 2004-02-03 Length [km] page 15

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.1 Test methods – Downhill test (3)

Downhill test - procedure

• „Qualifying“ of desired downhill track acc. to explained criterias • Calculation of compensation parameters such as speed, mass etc.

Top m = const. • nearly no instrumentation necessary P = const.

variable • performance of the downhill test run tan • measurement of the time needed

• if less then required time Æ DONE Bottom variable l Pittius 2004-02-03 page 16

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.2 Test methods – Towing test (1)

Specific criterias:

The braking force may vary due to retarder charactaristic The speed of the combination may due to Only small tolerances on the variation or force CD 12161 equivalant energy and time ! If the the towed vehicle has not fully laden the rolling but • tolerances on force variation resistance must be • tolerance on speed variation considered at the evaluation of the test. • compensation of GVW and rolling resistance

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.2 Test methods – Towing test (2)

Towing test - procedure

• „Qualifying“ of vehicles and test conditions • Compensation of rolling resistance and determination of requ. force • Instrumentation of vehicles necessary • performance of the towing test 12 min and data recording • postprocessing of test data Æ calculation of braking energy • if equal to equivalent energy Æ DONE Pittius 2004-02-03 page 18

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.3 Test methods –Dynamometer test bench (1)

Specific criterias: The braking force may vary due to retarder charactaristic The speed of the test bench may due to the variation or force Only small tolerances on If the the measured vehicle is CD 12161 equivalant energy and time ! not fully laden the rolling resistance must be but • tolerances on force variation considered at the • tolerance on speed variation evaluation of the test. A cooling device must • compensation of GVW and simulate the air stream rolling resistance due to the vehicle speed Pittius 2004-02-03 page 19

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6.3 Test methods –Dynamometer test bench (2)

Simulation test - procedure

• „Qualifying“ and instrumentation of the test bench • Compensation of rolling resistance and determination of requ. force • performance of the towing test 12 min and data recording • postprocessing of test data Æ calculation of braking energy • if equal to equivalent energy Æ DONE

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 7 Specific test parameters for engine brakes (1)

Speed tolerance 30 ± 5 km/h

-1 Getriebe: ZF S6-90 n Mot-min/max 1200 / 2000 min Rdyn 0,502 m Masse 18000 kg iHa 3,33 fr 1,0 %

Bremsmoment [Nm] Verzögerung [%] 5.000 100 kW 200 kW 300 kW 400 kW 500 kW 600 kW 19,0

4.500 Comparison Exhaust Brake vs Secundary Retarder 1. Gang 17,0 ¾ All primary retarders shall 4.000 15,0 3.500 Average (engine = 1600 min-1) Voith Retarder 133-2 (3750Nm) be treated same as engine 13,0 3.000

2. Gang 11,0 retarders 2.500 9,0 2.000

Type IIa 7,0 • because they operate 1.500 3. Gang● 1.000 4. Gang 5,0

5. Gang 500 3,0 via the gearbox as well 6.Gang

Source: Voith Analysis 0 1,0 Pittius 2004-02-03 0 102030405060708090100pagev [km/h] 21

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 7 Specific test parameters for engine brakes (2)

Deceleration test ≥ 0.6 m/s²

¾ The deceleration test is NOT covered by the ISO CD 12161 • because this test is not „in line“ with the general idea of the equivalent energy

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 6 Conclusion (1)

• ISO CD 12161 • provides detailed definitions of three test procedures according to the principle of equivalent energy • the test procedures have been harmonized based on the principle of equivalent energy • allows adequate and individual decisions on the test procedure. It does not need high-end test facilities • considers primary retarders in the same „family“ as engine retarders because all are operating via the gearbox • does not cover the deceleration test in ECE-R 13

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161 ISO/CD 12161 ISO TC 22/SC 2/WG Secretariat: BNA Road vehicles — Endurance braking systems of motor vehicles and towed vehicles — Test procedures Véhicules routiers — Véhicules à moteur et véhicules tractés disposant de systèmes de freinage d'endurance — Procédures d'essai

Warning

This document is not an ISO International Standard. It is distributed for review and comment. It is subject to change without notice and may not be referred to as an International Standard.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to provide supporting documentation.

Thank you for your attention

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ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161